Catalytic conversion



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issuers. S m ?5' 6: i

'10, is elatedi toa prbes brc n fluoriderfllnfthe"reaotin aone ofjmycracking vvertlng' hydrocarbon, oils'fwherein highly heated; process and then lntroduce silicon tetrafluoride vapors otjth' sp" eijpas'sed "'in' contaot with aw gas, permitting'the Catalyst to be formed on the catalyst acoeleiates the oonversiomfandto" "fsu'rfaceof e material inthexreaetion zone.- I

'iorrlntoj g'asollne of for my catalyst such'jassilioa sand, silica gel, r i't may suitably be. charcoal, bauxite,ahlm i ajelgkleselguhr, fullers 1 L ,ve."g'., heavyhaphtha, on the surface of thecarri'erby-thewet method peraturejllsl ordinarily. ernployed -j'than for T with the carrier orother. ingredient.

, One, of the obj s's ,is to'oonvert is used-i0) eIOrmih'gjgdsblin; :a. .higher.tem-. ffluosilicate may be-m illed or'mixed intimately dition agent with other hydrocarbon conversion 15 patalysts. For example, I may -m1x *a minor li or a r a ively ,r necessary. Anothrgohjecto provide a re eater forming, lnwhiohtheprodu tlo Y carbonaceous" material is relatively small, gthus reducing the 1053'. 15011 sis-represente by T andwith various-metal oxides such asaluminum fparbon'andrgo aluminum bit-magnesium oxide in-eombination vyithiactive silica. in preparing these combination catalysts, v the aluminum fluosilic'ate is prefrablyfadded to the catalyst in amounts of about "fluo'silieate promoter has been found to intlieactivity-of the catalyst to which it is carbon ac ooks suehas gas oil, kerosene or heavy I 7 through the catalyst disposed in a porous bed Thecata1yst'may be retained in a restricted 'zohe provided with suitable temperaturei control means in order to regulate thetem- @oilvapors." a

- The conversion reaction is usually endothermic v and'requlres the introduction of additional heat. In of heavy naphtha conversion, I may employ somewhat higher temperatures, erg 850 v also be pregent-aene'ralb in an amount or about 7 v v Ito ivolumes'perf :volume of naphtha vapor I m employ a in the treated. Ingmar-a1. I prefer to conduct the conm m an ,m, 1 my dispose aluminum in version operation at relatively low pressures. for

1d-e onversion.-'-Theprooess'may 2 "may use various supports or so-called carriers "r ibrm e s o fearth, etc., and maritime-ma be deposited theknoelrratirig: When the process orby the method just'desoribed'or the aluminum -I may employ alumlnumifiuosilicate as an ad- Y proportion of aluminum fiuosilioate with activated clay such as Super.Filtro1, withs'ilica gel 'i1'1ox'idermagnesium oxide, titanium fokide and 10%.1Qrasm'uch as to The aluznland alsoreducethe formation or fixed my process-I prefer employ: m lt'ely' Vaporizableoils or so-calledaolean the case of g'as oil, I- prefer to spa m temperature ofvab'out800 to orexample' 925 and conduct the fperature of the'vapors undergoing "conversion or the catalyst may be suspended as a powder in the .m 1100 1 Ior example, 1000 1''. Hydrogen may example, 5 to 50 pounds per square inch. although higher pressures may be employed i1 desired such as 100 to 500 pounds per square inch. The time of contact of the hydrocarbon vapors with the catalyst expressedas space velocity is usually about 0.2 to 10 volumes of liquid oil per volume or catalyst per hour. A space velocity within the range of about 0.5 to 5 volumes of liquid hydrocarbon charged per gross volume of catalyst per hour is typical.

After the hydrocarbon vapors have contacted the catalyst they are passed to a suitable fractionating apparatus where the gasoline is separated from the heavy hydrocarbons and the latter may be recycled to the conversion process except in the case of gasoline reforming, inwhich case the process is best operated on the once through" basis. The gasoline fraction is separated from undesirable fixed gases such as propane and, if desired, the gases, especially'hydrogen-c'ontaining gases, may be recycled also to the conversion process.

The following data will illustrate the results obtained in one run with my aluminum iiuosilicate catalyst. The oil treated was 35 A. P. I. Mid-Continent gas oil. a

Catalyst g Run 2 Weight oi catalyst, gms 57. 7 Vol. of catalyst space, 0. c. 117. Cracking temperature, F 925. 0 925. 0 Pressure. Atmospheric Feed rate 0. e. per hour 141.0 Vol. of feed per vol. of catalyst chamber per hour 1. 20 Bbls. (42 gals.) feed per ton of catalyst l3. 9 Time of contact, secs 8. 6 9. 8 Length of run, hours 6. 02 5. Recovery, wt. per cent of feed 98. 2 Once through yields- Dry gas, wt. per cent 1.43 1.61 Gasoline, vol. per cent. 9.07 h 8 Cycle stock, vol. 87. 7 Gasoline produce per hour 12. 8 Gas, lbs. per gal. of gasoline 1.11 Gas, on. it. per gel gpecliic gravity dry gas (air-1) asoline, end point Gravity, A. P. I.. 55.9 Knock rating, A. S. T. M. (irom blends). 84. 4 77. 0 Unsaturates, r cent 70. 5 88. 3 Refractive in ex.- Cycle gas oil-End Point,

Gravity, A. P. I 50% point (A. B. 'l. M. distillation)---" Unsaturates, 1- cent Refractive in ex .-I

One of the outstanding characteristics or my new hydrocarbon conversion catalyst is the negligible amount of carbonaceous deposit which forms on the catalyst. In run 2 above, the carbon formed on the catalyst was only .03%. .Accordingly, with this catalyst it is possible to make longer runs with less frequent-shutdowns for re.

generation oi the catalyst. Regeneration is usually accomplished by burning the carbon from or aluminum nuosilicate. The results are as follows:

Run No.

Catalyst 10 super 8 F lit 1 F33 (Aw-$407? s [rain on iii, in). n

Bpsce velocity 0. 97 1. l2 0. 00 Lengthrun,hours 5.5 5.6 6.5 Gasoline, percent by volume 24.7 I 20.7 20.5 82 ifitfii? "ii -2" 1 1: 0 in: 0 53 martinis? m 31.5 It will be noted rrom these data that the catalyst promoted with aluminum fiuosilicate produced more gasoline and less gas as indicated by the gas to gasoline ratio. The improvement in the knock rating is also significant.

In another example, gas oil or 35.5 A. P..I. was a cracked to about the same gasoline yield using three diflerent catalysts and the carbon rormation was found to be very much less with the aluminum fluosilicatecatalyst. The data tollow:

so Run No.

a Catalyst Bilim gel Silica gel 3 .ii, si m Alt l fi o Gasoline, vol. per osni. 1M8 35.0 Carbon, wt. per cent 0.8 1.8 1.2 Knock rsting.A. s.r.M 79.5 30.0 no

Theiollowing data illustrate still further the low carbon forming tendency of nuosilicate treated catalysts. Mid-Continent gas oil 'of 35.5 A. P'. I. was cracked for 2-hour reaction periods 'at a space velocity of 1. The results follow:

Catalyst Silica hydro- Biliea hydro- AK fie)! 026 860 ms 060 i M. 4 so. 7 03. 4 37. 9 l6. 9 6. b 13. 8 7. 6 l3. 0 4. 3 ll. 7 4. I 3. 0 2. 4 I. l 1. I 36. 7 58. 2 40. 4 86. I so. 1 70. 9 K). 6 70. I

In preparing my catalyst Ipreier to incorporate the aluminum Iiuosilicate in other hydrocarbon conversion catalysts, particularly the The following is an example showing the beneficial effect of aluminum fluosilicate added to another catalyst, in this case Super Flltrol, an acid activated montmorillonite clay. Ten percent metal oxide gels such as silica gel, alumina gel or magnesia gel or combinations of them. Thus, I may thoroughly mix the aluminum iiuosilicate with silica hydrogel prepared from sodium silicate solutions and an acid. .Undesirable soluble salts should be washed iron: the hydrogol beione mixing with the aluminum fluosilicate. Mixing may be accomplished by grinding in a ball mill to produce a very thorough intimate mixture. The amount or aluminum rluosilicate used in this way will ordinarily beabout 5 to 25%.

In addition to the aluminum fluosilicate I may add to the silica hydrogel, magnesium oxide or aluminum oxide, preferably in an amount of about 1 to 30%. All three ingredients may be mixed simultaneously after whichthe gel mixture is dried, pelleted or graded to produce the desired granular catalyst or it may be ground to a fine powder where the catalyst is intended ,to be used as a suspension in the hydrocarbon vapors,

The alumina employed in preparing the mixed catalysts just described may be an alumina gel prepared by coagulation of alumina sol derived from the action of dilute acid on metallic aluminum or by the action of acid on sodium aluminate or other suitable salt. Alumina suitable for preparing a mixed catalyst as described above may also be prepared by treating an aqueous solution of a salt of aluminum such as aluminum sulfate with a base material. I prefer to employ in my catalyst fluosilicate of aluminum, but other fiuosilicates may be employed such as mag-' nesium, beryllium, cerium, and thorium fluocatalyst consisting essentially of a mixture of active silica and alumina containing about 1 to 50% of'aluminum fluosilicate in mechanical admixture with said active silica and alumina.

silicates, and ingeneral, the fluosilicates of the metals of groups II, III and IV of the periodic system. 7

Although I have described my invention with respect to certainapplications thereof, I intend that it be definedonly by the following claims. -Iclaim: V

1. In the process of converting hydrocarbon oils into high knock rating gasoline wherein said hydrocarbon oils are vaporized and the Vapors are subjected to the action of a solid porous conversion catalyst at conversion temperature with accompanying deposition of carbonaceous deposit on said 'catalyst;= the improvement comprising 2. The process of converting hydrocarbon oils into high knock rating motor fuels which corri-v prises subjecting said oils at conversion temperature to the action of a conversion catalyst consisting essentially of an intimate mixture of silica gel and aluminum fluosilicate.

3. The process of convertingv hydrocarbon oils into high knock rating motor fuels which com- "prises subjecting said oils at conversion temperature to the action of a hydrocarbon conversion 4. The process of converting hydrocarbon oils comprising contacting said oils at conversion temperature with a solid catalyst consisting essentially of a fiuosilicate of a metal selected from the class consisting of groups two, three and four, of the periodic system.

5. The processiof converting hydrocarbon oils into high knock rating motor fuels which com-' prises subjecting said oils at conversion temperature to the action of a solid metal oxide hydrocarbon conversion catalyst stabilized bythe addition of at least 1% of a fluosilicate of a metal selected from the class consisting of groups II, III and IV of the periodic system in admixture therewith and thereafter separating said high knock rating motor fuel from the conversion.

products. v

6. The process of converting hydrocarbon oils into high knock rating motor fuels which compri'ses'subjecting said oils at conversion temperature to theaction of a solid metal oxide hydrocarbon conversion catalyst stabilized by the addition ofxat least 1% of aluminum fiuosilicate in comprises subjecting said oils .at a temperature in the range of about 800to1025 F. to the action of a solid metal oxide hydrocarbon conversion catalyst stabilized by the addition of at least 1% of aluminum fluosilicate in admixture therewith and thereafter'separating said high knock rating motor fuel from the conversion products.

8.'The process of increasing the knock rating of straight-run gasoline and fractions thereof comprising subjecting the vapors of said gasoline at a temperature of about 850 to 1100" F. to the action of a hydrocarbon conversion catalyst stabilized by the addition of about 1 to 50% of alu minum fluosilicate in admixture therewith, fractionating the resulting products and separatin the desired high knock rating gasoline therefrom.

MELVIN J. SEE. 

